SYSTEM SOLUTIONS FOR SHEET EXTRUSION LINES SOLUTIONS FOR SHEET EXTRUSION LINES Sheet extrusion of...

SYSTEM SOLUTIONS FOR SHEET EXTRUSION LINES

Sheet extrusion of polyolefins and engineering thermoplastics

IN PARTNERSHIP WITH INDUSTRY

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide

Whatever you aim to achieve in plastics or rubber

processing, KraussMaffei is your partner. We are

the only company with intensive expertise across

the three main engineering fields. And we have a

strong track record in integrating this expertise to

develop new processes and systems.

Ready for any challenge

Our Injection Molding Machinery Division

supplies machinery and systems from 35 to 4,000

tonnes for standard applications and for all

processing variants, together with fully automated

solutions. We have a strong customer base in all the

relevant industries worldwide.

Our Reaction Process Machinery Division supplies

machines and complete systems for processing

polyurethanes and other reactive materials.

Completing our product portfolio, Automotive

Component Systems supplies foam molds, cutters

and routers. Our customer base is wide, with a

focus on the automotive, construction and white

appliances industries.

Our Extrusion Technology Division supplies

machinery and systems for compounding, for pipe,

profile and sheet extrusion, physical foaming, and

the production of technical rubbers and inter-

mediates for tire production. Machinery from the

company’s range – from single extruders to

complete extrusion lines – is used in many

industries, including chemicals, pharmaceuticals,

automotive, construction, furniture and packaging.

People for Plastics

We are the “people for plastics”. We are your

partners from the first exploratory discussion,

through development to commissioning, servicing

and operating your system, and final disposal. At all

times, you are assured of outstanding competence

in planning and engineering, as well as reliable and

fast spare parts, service and support.

Adding value for customers

We put our expertise to work for your success.

With machine ranges engineered for modular-

ity, we can deliver application-specific solutions

based on our wide range of standard modules and

specially engineered solutions. This strategy offers

customers technical and cost advantages.

Close to customers around the world

As an international company, KraussMaffei has

a presence in all the major markets for the plastics

and rubber processing industries and employs

around 3,000 people worldwide. Our sales and

service network keeps us close to all our

customers around the world.

Electrical / ElectronicsLife SciencesConstructionWhite GoodsAutomotive

Electrical / Electronics Packaging

Integrated system solutions for a huge range of PO sheet products

The use of polyolefins has been growing steadily for decades and the trend continues. One important growth area is in extruded sheet.

KraussMaffei Berstorff’s 36D single-screw extruders are ideal for extruding polyolefin sheet – both compact and foamed. We’ve got what it takes for successful production. Firstly, we supply complete integrated system solutions for a huge range of PO sheet products. Secondly, we have the intensive process and application experience and the comprehensive engineering expertise you would expect from a system supplier. It’s all at your service.

TRANSPARENT TECHNOLOGY

Take a tour of a possible configuration for a sheet extrusion line

Edge trim hacker

Longitudinal parting sawwith servo-drive, pneumatic positioning of the cutting blade and the swarf extraction unit

Roller cooling section

Haul-off Single- or double-strand haul-off, pneumatic positioning of the rubber-covered rolls, adjustable speed differential to polishing stand

Swarf extraction

Stacker with roller table

Crosscut saw or router with servo-drive

· Screen changer

· Melt pump

· Static mixer

· Protective film above

and/or below

· Laminating unit

· Embossing unit

· Corona treatment

· Thickness monitoring

Other options on

request

Optional system components

Temperature-control unituses water or oil as medium

Slit die

Single-screw extruderKME 150-36 B/PL for PO with gravimetric material feed (one to four components)Extruder shown without switch-ing cabinet or C5 control unit

Polishing standwith high-gloss, chrome-hardened rolls, individual servomotor drives and planetary gears, nip monitoring via electronic sensors, constant temperature profile over the whole width of the roll

Radiant heaterCombination of area and point heaters, adjustable zone regulation

Pressure rollfor optimizing flat-ness (temperature control and drive optional)


Many market segments and application areas are

turning increasingly to polyolefin sheet: Be one

step ahead of the competition with KraussMaffei

Berstorff.

Complete system solutions from the world’s

leading system supplier

KraussMaffei Berstorff has long been a world-

leading system supplier of PVC sheet extrusion

lines. In recent years, we have systematically

expanded our product portfolio. We offer com-

plete system solutions for processing different

PO sheet grades and custom PO materials. Our

machinery and process know-how can give you

a decisive competitive advantage, because we

configure and supply complete sheet extrusion

lines using high-quality components and extensive

automation. The advanced screw geometries are

a hallmark of our 36D single-screw extruders.

The screws maintain the constant pressure, high

output and uniform temperature profile essential

for the process. The extruder can also be operated

without a melt pump.

Dedicated systems for foamed PO sheet

Chemically foamed PE and PP sheet is finding a lot

of new applications, and it is also helping to cut the

cost of raw materials for products that are already

on the market. To meet high quality specifications,

the extruded foam must have a homogenous internal

structure and smooth outer surfaces. For the best

foam quality, the melt must leave the extruder as

a highly homogenous compound with the blowing

agent (added as microgranules) uniformly distrib-

uted. The melt, which is under pressure, expands

immediately on exiting the die.

36D single-screw extruders are ideal for extruding

foamed PO sheet. Such sheet has a closed pore

surface while the internal core cross-section has a

homogeneous, cellular structure. Foam formation

is triggered by subjecting the blowing agents to

heat. The complex combination of the formulation,

the plasticizing process and the special geometry

of the slit die lips produces foamed sheet with far

lower density than compact sheet. Raw materials

consumption is reduced in proportion. KraussMaffei

DETAILED PRODUCT INFORMATION

Benchmarks for PO sheet production – with 36D single-screw extruders

Fast gap and deckling systemsAdjustable coextruder adapterPO sheet die

Output in sheet extrusion [kg/h]

Extruder type HDPE PP

KME 45-36 B/PL 140 140

KME 60-36 B/PL 220 220

KME 75-36 B/PL 320 320

KME 90-36 B/PL 400 400

KME 105-36 B/PL 500 500

KME 125-36 B/PL 630 630

KME 150-36 B/PL 800 800

KME 200-36 B/PL on request on request

Berstorff supplies a dedicated extrusion unit for this

foaming process: it consists of a 36D single-screw

extruder with grooved bush and barrier screw, a

screen changer (option) and a slit die specifically

designed for foamed PO sheet.

Detailed product information

Eccentric feedAvoids turbulence and maximizes output

TRANSPARENT TECHNOLOGY

Meet the machine: take a tour of a 36D single-screw extruder

Rugged gearingLong life, lowest maintenance costs and space savings (gearbox and motor form a U)

Gravimetric material weighing system

Deep-nitrided grooved bushOutstanding cooling performance, lowest cooling water consumption, steady material feed – independent of counterpressure – and self-cleaning

Bimetallic barrelLowest wear rates

Barrier screwFor thermal and materially homogenous melt and low melt temperatures

Optimal drive dimensionsDC (standard) or AC (option), air-cooled (standard) or water-cooled (option)

Detailed product information

Mobile operator panel

(option)

KraussMaffei Berstorff standard operator panel:

integrated in the control cabinet

Swivel-mounted operator panel (option)

DETAILED PRODUCT INFORMATION

The C5 control – one of the most advanced control and monitoring systems in the industry

Centralized control of the extrusion line

Meeting tough specifications for product quality and

output demands a stable, reliable production process.

This is where the C5 control system scores. As one of

the most advanced systems in the industry, it offers

dependable technology and intelligent functions for

centralized control and monitoring of extrusion lines.

For the operator, the C5 ensures optimal set-up and

start-up, and a clear, consistent overview of the pro-

duction process. Monitoring and control is facilitated

by efficient visualization of the status of different

extrusion line components on a series of screen pages.

Central synchronization of the whole line, including

multiple extruders, is fast and simple. The operator

panel allows direct intervention in the operation of

all key elements in the extrusion line. The current

operating status of the whole line is always displayed,

together with a customizable selection of seven actual

parameters. Prompts and alarm messages flash up

in your chosen language. The C5 offers extensive

documentation options and easy connection to a host

computer. The standard design features an integrated

operator panel; swivel-mounted or mobile panels are

offered as options. The swivel-mounted panel, for

example, enables the operator to run the whole line

from a position near the die.


No matter how varied and specialized your PO

sheet production needs may be, KraussMaffei

Berstorff’s 36D single-screw extruders are more

than equal to the job.

Processing materials for a broad product range

The screws in our 36D single-screw extruders

have been engineered to deliver decisive advan-

tages in terms of product quality, productivity

and costs. With KraussMaffei Berstorff sheet

extruders, you can process materials for a whole

range of products, especially those used to make

water tanks and acid tanks.

HDPE sheet – unbeatable advantages in count-

less applications

HDPE sheet resists stress cracking, has low-tempera-

ture impact resistance, very good energy absorption,

high stress resistance, outstanding corrosion and

abrasion resistance, low water absorption and very

good electrical isolation properties. With a property

profile like this, it’s the material of choice for a broad

range of applications. Here are some of the products

that can be made of HDPE:

· Rotor blades

· Roller bearing bodies

· Storage containers

· Shuttering

· Wash basins

· Machine parts

· Seating

· Medical prostheses

· Chopping boards for the food processing industry

· Shipbuilding

APPLICATIONS AND CUSTOMER BENEFITS

All set for the markets of the future – tap into lucrative potential with new applications

HDPE sheet is used in shipbuilding Acid tank made from PP sheet

PP-H dialysis boards

PP sheet – attractive advantages for many

applications

PP is light, offers optimum abrasion resistance,

has excellent electrical characteristics, withstands

long-term exposure to temperatures up to 90°C,

has a high surface hardness, can be nailed and

welded, and is thermoformable. It can be used in a

broad range of applications. Here are some typical

products:

· Battery housings

· Acid tanks

· Liners

· Laboratory dishes

· Mechanical components

· Shuttering

· Transport pallets

· Kitchen equipment

· Sterilizable components

Applications and customer benefits

Various kinds of extruded

PO sheet, mono or

coextruded in multiple layers

Your benefits at a glance:

· Conveying behaviour independent of counter-pressure at all speeds

· Low melt temperature levels due to high specific throughputs

· Excellent plasticizing performance

· Gentle melt processing and optimal homogeneity

· Long life through optimized pressure profiles and low wear rates

· Clear reduction in cooling water consumption for the grooved bush

· Low-maintenance drive in proven U arrangement

· Compact machines with a small footprint

· Outstanding price/performance ratio

Rely on us for a fast and competent response to

all your service needs anywhere in the world.

Whatever you need – from troubleshooting and

training to spares or repairs – we’re on the job.

We’re dedicated to supplying service quality on a

par with the outstanding quality of our machines

and systems. We offer far more than spare parts

and hotlines. We’ll work with you to choose the

best and most cost-effective solution for your

operation. We’ll help you test new applications

and we’ll plan customized service packages.

All-round service

Our service offering is broad. We’ll configure your

system, install and commission it, train your staff,

plan measures to minimize your downtime risk and

maximize productivity, and carry out maintenance,

repairs and upgrades. You’ll find us fast, reliable

and competent. Our hotline is manned by highly-

trained and experienced service technicians.

If necessary, we’ll get a technician to you quickly.

Remote diagnosis, interfacing directly with your

machine’s control system, can be a practical

alternative. Spares for all important wear parts are

available at short notice. We’re continuously

expanding our service network to speed up spare

parts shipment. Talk to us about the right service

solution for your business.

Customer trials and prototyping in our test lab

The Extrusion Division operates a test lab fitted

with the latest machinery and equipment. We can

run trials, produce prototype parts and fine-tune

processes on your behalf. We can work with you

to test and evaluate processes, machines and

equipment in order to identify the best approach

for a particular project. Our highly-qualified

application engineers are there to help you.

Training with high hands-on content

Courses are held in our lab and training centre,

or, optionally, on your premises. We offer

clearly-structured basic and advanced training in

operation, process control and maintenance for

KraussMaffei extrusion systems. On request, we’ll

plan and hold special courses on topics of your

choice. All participants spend a high proportion

of their training working hands-on with original

KraussMaffei machines. A well-structured

training program produces skilled operators

and technicians, which will positively impact

your up-time and productivity.

SERVICE WORLDWIDE

Service, support and spare parts – when you need them, where you need them

Worldwide hotlineWorldwide hotline numbersnumbers

Extrusion Technology ServiceExtrusion Technology Service

KraussMaffei Technologies GmbHKraussMaffei Technologies GmbH

Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2

80997 Munich80997 Munich

GermanyGermany

Contacting us by postContacting us by postIf you need to contact any of our

international service or spare parts teams

by post, use this address:

KraussMaffei Technologies

India Pvt. Ltd.

Pune, India

Phone: +91 20 41404610

Fax: +91 20 414046 99

Email: [email protected]

Krauss-Maffei Extrusion

Technology (Zhejiang) Co., Ltd.

Jiaxing City, China

Phone: +86 573 86973888

Fax: +86 573 86967111


KraussMaffei Technologies GmbH

Munich, Germany

Customer Service

Phone: +49 89 8899-2273 (electrical systems)

Phone: +49 89 8899-4380 (mechanical systems)


Application Engineering

Phone: +49 89 8899-4094

Fax: +49 89 8899-2161


Krauss-Maffei Italiana S.r.l.

Abbiategrasso, Italy

Phone: +39 02 94963181

Fax: +39 02 94699482


Berstorff Krauss-Maffei OOO

Moscow, Russia

Phone: +7 495 9377554

Fax: +7 495 9701731

Email: [email protected] Krauss Maffei Corporation

Florence, USA

Phone: +1 859 2834307

Fax: +1 859 2830290


Krauss Maffei de México

S. de R.L. de C.V.

Mexico City, México

Phone: +52 55 53082383

Fax: +52 55 53081727


Krauss Maffei do Brasil Ltda

São Paulo, Brazil

Phone: +55 11 46129171

Fax: +55 11 46128366


Krauss-Maffei (U.K.) Ltd.

Warrington, UK

Phone: +44 1925 644100

Fax: +44 1925 234284


KraussMaffei Technologies GmbH

Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-2546 ··· Fax +49 89 8899 - 4043www.kraussmaffei.com

KraussMaffei is a premium partner for the plastics and rubber processing

industries worldwide. KraussMaffei machines and systems are used wherever

plastics and rubber are converted into products. As a knowledge-driven

technology company, we build on many decades of experience and a strong

commitment to research and development.

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The 36D single-screw extruders from Krauss-Maffei Berstorff are ideal for extruding polyolefin sheet – whether compact or foamed. We‘ve got what it takes for successful production. Firstly, we supply complete integrated system solutions for a huge range of PO sheet products. Secondly, we have the intensive process and application experience and the comprehensive engineering expertise you would expect from a system supplier. It’s all at your service.

SYSTEM SOLUTIONS FOR SHEET EXTRUSION LINES SOLUTIONS FOR SHEET EXTRUSION LINES Sheet extrusion of...

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